Fabric cleaning article with texturing and/or a tackiness agent

ABSTRACT

Articles designed to clean/refresh soiled fabrics are improved by means of texturing at least one surface and/or by applying tackiness agents. In use, the articles rub against the fabrics, whereupon lint removed from the fabrics is trapped and retained by the tackiness agent. Refolding of the articles during use is substantially minimized by imparting texture to one or more of the article&#39;s surfaces.

RELATED APPLICATIONS

This application is a 371 of International Application Serial No.PCT/1B98/01414 filed Sep. 14, 1998 which claims priority under 35 U.S.C.§119(e) to U.S. Provisional Application Ser. No. 60/077,556 filed Mar.11, 1998.

TECHNICAL FIELD

The present invention relates to articles which are designed to cleanfabrics in a non-immersion cleaning process.

BACKGROUND OF THE INVENTION

By classical definition, the term “dry cleaning” has been used todescribe processes for cleaning textiles using nonaqueous solvents. Drycleaning is an old art, with solvent cleaning first being recorded inthe United Kingdom in the 1860's. Typically, dry cleaning processes areused with garments such as woolens which are subject to shrinkage inaqueous laundering baths, or which are judged to be too valuable or toodelicate to subject to aqueous laundering processes. Various hydrocarbonand halocarbon solvents have traditionally been used in immersion drycleaning processes, and the need to handle and reclaim such solvents hasmainly restricted the practice of conventional dry cleaning tocommercial establishments.

Together with the soil and stain removal aspects of a typical drycleaning process, there is also a consumer need for what can be termedfabric “refreshment” compositions and processes. Thus, fabrics whichhave lint, hair or other solid debris clinging to the fabric surface,and which may have adsorbed malodors, have become wrinkled, or haveotherwise lost their fresh appearance, are often subjected toconventional commercial dry cleaning processes mainly to reestablishtheir freshness aspect.

Attempts have been made to provide in-home dry cleaning systems. Onetype of in-home system for cleaning and refreshing garments comprises acarrier sheet containing various cleaning agents and a plastic bag. Thegarments are placed in the bag together with the sheet, and then tumbledin a conventional clothes dryer. In a commercial embodiment, multiplesingle-use flat sheets and a single multi-use plastic bag are providedin a package. Unfortunately, such in-home processes are sub-optimal withrespect to the removal of lint and other solid debris from fabricsurfaces.

For purposes of convenience and economics, the carrier sheet for use inthese home dry cleaning processes is often folded one or more times toallow for smaller shipping and storage packaging. But in use, thesecarrier sheets tend to refold along the crease lines resulting inreduction in the exposed surface area of the sheet. With less exposedsurface area the efficiency of these sheets is substantially reduced,resulting in reduced cleaning and refreshing.

PCT Application US 96/02886, published Oct. 3, 1996, to Maxwell Davis,discloses the problems associated with such sheet re-folding in anin-home, non-immersion cleaning/refreshment process. The patenteedescribes the use of macroscopic holes punched through the sheets tohelp prevent re-folding. However, punching holes in the sheets requiresan extra processing step during manufacture, at added expense. U.S. Pat.No. 5,630,848, issued May 20, 1997 to Young, Bavely, Roetker & Davis,discloses the use of HYDRASPUN® sheets and bespeaks the advantage thatre-folding is minimized, as compared with conventional non-wovens.However, the re-fold problem is not completely solved. Moreover, whenthe HYDRASPUN® sheets are enrobed in a fibrous coversheet, as disclosedhereinafter, re-folding can again become problematic. Hence, thereremains a continuing need for carrier sheets and methods of formingthese sheets which minimizes refolding of the sheets during use.

The present invention provides improved pick-up and removal of lint andother particulate matter from fabrics which are being cleaned and/orrefreshed, or fugitive lint in the bag, and substantially reduces theoccurrence of refolding of the carrier sheet. These benefits are securedwhen a carrier sheet that releasably contains a cleaning/refreshmentcomposition is textured, is covered with a coversheet material that istextured and/or which is treated with a tackiness agent, as disclosedhereinafter. In a preferred mode, the tackiness agent is placed on theinner surface of the coversheet, thereby avoiding damage to the fabricsbeing cleaned/refreshed.

BACKGROUND ART

WO 97/00993A1, published Jan. 9, 1997 to Weller, et al.; WO 97/00990A2,published Jan. 9, 1997 to Tyerech, et al.; GB 2,302,553A, published Jan.22, 1997 to Telesca, et al.; GB 2,302,878A, published Feb. 5, 1997 toWeller, et al.; and GB 2,302,879A, published Feb. 5, 1997 to Sidoti, etal. all relate to in-dryer fabric cleaning. U.S. Pat. No. 4,532,722,issued to S. H. Sax, Aug. 6, 1985, relates to a fabric conditioningdevice for use in a laundry dryer. A peracid-containing dry cleaningcomposition is described in U.S. Pat No. 4,013,575, issued to H.Castrantas, et al., Mar. 22, 1977. Dry cleaning processes are disclosedin: U.S. Pat. No. 5,547,476 issued Aug. 20, 1996 to Siklosi & Roetker;U.S. Pat. No. 5,591,236 issued Jan. 7, 1997 to Roetker; U.S. Pat. No.5,630,847 issued May 20, 1997 to Roetker; U.S. Pat. No. 5,630,848 issuedMay 20, 1997 to Young, et al.; U.S. Pat. No. 5,632,780 issued May 27,1997 to Siklosi; EP 429,172A1, published May 29, 1991, Leigh, et al.;and in U.S. Pat. No. 5,238,587, issued Aug. 24, 1993, Smith, et al.Other references relating to dry cleaning compositions and processes, aswell as wrinkle treatments for fabrics, include: GB 1,598,911; and U.S.Pat. Nos. 4,126,563, 3,949,137, 3,593,544, 3,647,354; 3,432,253 and1,747,324; and German applications 2,021,561 and 2,460,239, 0,208,989and 4,007,362. Cleaning/pre-spotting compositions and methods are alsodisclosed, for example, in U.S. Pat. Nos. 5,102,573; 5,041,230;4,909,962; 4,115,061; 4,886,615; 4,139,475; 4,849,257; 5,112,358;4,659,496; 4,806,254; 5,213,624; 4,130,392; and 4,395,261. Sheetsubstrates for use in a laundry dryer are disclosed in Canadian1,005,204. U.S. Pat. Nos. 3,956,556 and 4,007,300 relate to perforatedsheets for fabric conditioning in a clothes dryer. U.S. Pat. No.4,692,277 discloses the use of 1,2-octanediol in liquid cleaners. Seealso U.S. Pat. Nos. 3,591,510; 3,737,387; 3,764,544; 3,882,038;3,907,496; 4,097,397; 4,102,824; 4,336,024; 4,594,362; 4,606,842;4,758,641; 4,797,310; 4,802,997; 4,943,392; 4,966,724; 4,983,317;5,004,557; 5,062,973; 5,080,822; 5,173,200; EP 0 213 500; EP 0 261 718;G.B. 1,397,475; WO 91/09104; WO 91113145; WO 93125654 and Hunt, D. G.and N. H. Morris, “PnB and DPnB Glycol Ethers”, HAPPI, April 1989, pp.78-82.

SUMMARY OF THE INVENTION

The present invention encompasses an article for treating fabrics,comprising:

a) an absorbent substrate having a first surface and a second surface;

b) a liquid cleaning/refreshment composition releasably absorbed in thesubstrate;

c) the substrate being wholly (preferred) or at least partly covered bya coversheet, preferably a fibrous coversheet, which is permeable to thecleaning/refreshment composition in the liquid or vapor state, thecoversheet having an external surface and an internal surface, thearticle comprising a tackiness agent which can be on the surface of theabsorbent carrier substrate, on the coversheet, or on both the substrateand the coversheet.

In a preferred embodiment of this invention there is provided an articlefor treating fabrics, comprising:

a) an absorbent substrate having a first surface and a second surface;

b) a liquid cleaning/refreshment composition releasably absorbed in thesubstrate; and

c) the substrate being wholly or at least partly covered by a coversheetwhich has an external surface and an internal surface and which ispermeable to the cleaning/refreshment composition in the liquid or vaporstate; and

wherein at least one of the cover sheet and the absorbent substrate havea texture imparting pattern of indentations on at least one of theirsurfaces, preferably the article also comprises a tackiness agent.

In another preferred mode the coversheet substantially envelops thesubstrate. In a highly preferred mode, the tackiness agent is on theinternal surface of the coversheet.

The cleaning/refreshment composition used herein can comprise water anda member selected from the group consisting of organic surfactants,organic solvents, auxiliary cleaning agents, and mixtures thereof. In apreferred mode, the cleaning/refreshment composition comprises water anda surfactant, especially a nonionic surfactant, e.g. an ethoxylatedalcohol or ethoxylated alkyl phenol surfactant.

The invention thus provides articles of manufacture in sheet form whichare specifically adapted to clean and/or refresh fabrics in a hot airclothes dryer, comprising:

(a) a core element which comprises a liquid absorbing carrier in sheetform;

(b) a liquid cleaning/refreshment composition comprising at least about95%, by weight, of water releasably absorbed in the core element;

(c) a permeable coversheet which enrobes the outer surfaces of the coreelement, the article containing the tackiness agent. In a preferredembodiment, the liquid absorbing carrier and/or the coversheet has atexture imparting pattern of indentations on at least one of thesurfaces of the liquid absorbing carrier and/or the coversheet.

Preferably the cleaning/refreshment composition comprises up to about2%, by weight, of a nonionic surfactant.

The invention also provides a cleaning/refreshment process for treatinga fabric, comprising the overall steps of:

(a) placing the fabric together with an article according to thisinvention in a containment bag, preferably of the vapor-venting type;

(b) placing the bag in a hot air clothes dryer and operating the dryerwith heat and tumbling; and

(c) removing the fabric from the bag.

It has surprisingly been found that by applying texture to the absorbentsubstrate, the coversheet, or both, the cleaning article made therefromrarely refolds during use. The cleaning article carries thecleaning/refreshing solution into the bag, and cleaning and refreshingof the fabrics occurs only after the solution evaporates from the sheet.Refolding of the cleaning article diminishes the exposed surface area ofthe article, which in turn diminishes the rate of evaporation of thesolution, resulting in less cleaning/refreshing vapors in the bag. Byavoiding refolding the textured cleaning articles of this invention aresubstantially more efficient at delivering the cleaning/refreshingsolution to the fabrics being cleaned and refreshed.

All percentages, ratios and proportions herein are by weight, unlessotherwise specified. All documents cited are, in relevant part,incorporated herein by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of the article herein in a pre-assembledstate.

FIG. 2 is a perspective of an assembled cleaning/refreshing article (1)of the present invention in sheet form.

FIG. 3 is a perspective of the article loosely resting on a notched,vapor-venting containment bag which is in a pre-folded condition.

FIG. 4 is a perspective of the article within the bag which is ready toreceive the fabrics to be treated in a hot air clothes dryer.

FIG. 5 is a partial view of the notched wall of the bag and itsdisposition relative to the closure flap.

FIG. 6 is a perspective of an un-notched vapor-venting bag containing aloose cleaning/refreshment article of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The individual materials employed to assemble the fabriccleaning/refreshment articles of the present invention are commerciallyavailable. The terms used herein to describe such materials have theirconventional meanings. For purposes of clarity, certain terms usedherein are defined as follows.

By “tackiness agent”, “tackifying agent” or “tackifier” herein is meanta material which is used to impart adhesive properties to otherwisesubstantially non-adhesive materials, i.e., the coversheet herein. Saidanother way, such agents make the surface of the coversheet more stickyand adherent to solid matter such as lint, hair, dust, pollen, and thelike.

By “tack” herein is meant the pull resistance exerted by a materialadhering to two separating surfaces. Thus, in the present invention the“tack” of the surfaces of the articles means the ability of the articlesto pull, or otherwise remove, solid materials away from the surfacesacross which the article passes, rubs, or otherwise contacts.

By “internal surface” of the coversheet herein is meant that surfacewhich faces the absorbent substrate. By “external surface” herein ismeant that surface which faces away from the substrate, i.e., facesoutwardly from the article. It is this face which comes in directcontact with the fabrics being treated.

By “texture” herein is meant that at least one surface of the article,that is, at least one of the surfaces of the coversheet or the absorbentsubstrate, comprises macroscopic indentations. Preferably theseindentations are in a pattern, for example a crisscrossing pattern ofdiagonal lines, or an intersecting pattern of parallel horizontal andvertical lines. Moreover, random indentations, for example, dimples ofthe same or varying size, are acceptable for use in the presentinvention. As will be apparent to those skilled in the art,“indentation” is a relative term. That is, an indentation on one surfaceof a flat sheet may result in a protrusion on the opposite side of thesheet. Hence, as used herein “indentation” is intended to encompass bothindentations and protrusions, provide that they impart some macroscopictexture to at least one surface of the articles of this invention.

The indentations which give rise to the texture can be applied by anyappropriate means. For example, one or more of the substrates orcoversheets to be textured can be pulled over a roller having a raisedpattern on its outer surface such that the pattern is imparted to thesubstrate or coversheet material. A second roller can be used to applypressure to the sheet material to insure the texture is sufficientlypronounced. Other methods of imparting texture to the cleaning articlesof this invention will be known to those skilled in the art. While notwanting to be bound be any one theory, it is believed that the textureimparting indentations act like small hinges when applied to a surfaceof the cleaning/refreshment articles of the present invention. Whenthese small hinges intersect a hard crease, such as the creases formedwhen the articles of this invention are folded for packaging, the creasebecomes more pliable and the sheet is much less likely to refold alongthe crease.

By “cleaning” herein is meant the removal of soils and stains fromfabrics. By “refreshment” herein is meant the removal of malodors and/orwrinkles from the overall fabrics, or the improvement of their overallappearance, other than primarily removing soils and stains, althoughsome soil and stain removal can occur concurrently with refreshment.Typical fabric cleaning refreshment/compositions herein can comprisemore water (95-99.9%, preferably greater than 95% up to about 99%) andfewer cleaning ingredients than conventional cleaning or pre-spottingcompositions.

Carrier—When used in the in-dryer step of the present process, thecleaning/refreshment compositions are used in combination with anabsorbent carrier substrate, which is sometimes referred to herein as an“absorbent substrate”. The carrier releasably contains the compositions.By “releasably contains” means that the compositions are effectivelyreleased from the carrier onto the soiled fabrics as part of thenon-immersion cleaning/fabric refreshment processes herein. This releaseoccurs by contact between the substrate and the fabrics and/or byvolatilization of the composition from the carrier substrate through thevapor-permeable coversheet, or by a combination of vapor and liquidtransfer.

It is highly preferred that the carrier be in the form of an integralpad or sheet which substantially maintains its structural integritythroughout the process. Such pads or sheets can be prepared, forexample, using well-known methods for manufacturing non-woven sheets,paper towels, fibrous batts, cores for bandages, diapers andcatamenials, and the like, using materials such as wood pulp, cotton,rayon, polyester fibers, and mixtures thereof. Woven cloth pads may alsobe used, but are not preferred over non-woven pads due to costconsiderations. Integral carrier pads or sheets may also be preparedfrom natural or synthetic sponges, foams, and the like.

The carriers are designed to be safe and effective under the intendedoperating conditions of the present process. The carriers must not beflammable during the process, nor should they deleteriously interactwith the cleaning or refreshment composition or with the fabrics beingcleaned. In general, non-woven polyester-based pads or sheets are quitesuitable for use as the carrier herein.

The carrier used herein is most preferably non-linting. By “non-linting”herein is meant a carrier which resists the shedding of visible fibersor microfibers onto the fabrics being cleaned, i.e., the deposition ofwhat is known in common parlance as “lint”. A carrier can easily andadequately be judged for its acceptability with respect to itsnon-linting qualities by rubbing it on a piece of dark blue woolen clothand visually inspecting the cloth for lint residues.

The non-linting qualities of sheet or pad carriers used herein can beachieved by several means, including but not limited to: preparing thecarrier from a single strand of fiber; employing known bondingtechniques commonly used with nonwoven materials, e.g., point bonding,print bonding, adhesive/resin saturation bonding, adhesive/resin spraybonding, stitch bonding and bonding with binder fibers. If the tackinessagent is applied to the external surfaces of the substrate, this furtherreduces any tendency to shed lint.

The size of the carrier should not be so large as to be unhandy for theuser. Typically, the dimensions of the carrier will be sufficient toprovide a macroscopic surface area (both sides of the carrier) of atleast about 360 cm², preferably in the range from about 360 cm² to about3000 cm². For example, a generally rectangular carrier may have thedimensions (X-direction) of from about 10 cm to about 35 cm, and(Y-direction) of from about 18 cm to about 45 cm.

The carrier is intended to contain a sufficient amount of thecleaning/refreshment compositions to be effective for their intendedpurpose. The capacity of the carrier for such compositions will varyaccording to the intended usage. For example, pads or sheets which areintended for a single use in cleaning/refreshing fabrics will requireless capacity than such pads or sheets which are intended for multipleuses. For a given type of carrier the capacity for the cleaning orrefreshment composition will vary mainly with the thickness or “caliper”(Z-direction; dry basis) of the sheet or pad. For purposes ofillustration, typical single-use polyester sheets used herein will havea thickness in the range from about 0.1 mm to about 0.7 mm and a basisweight in the range from about 30 g/m² to about 100 g/m². Typicalmulti-use polyester pads herein will have a thickness in the range fromabout 0.2 mm to about 1.0 mm and a basis weight in the range from about40 g/m² to about 150 g/m². Open-cell sponge sheets will range inthickness from about 0.1 mm to about 1.0 mm. Of course, the foregoingdimensions may vary, as long as the desired quantity of thecleaning/refreshment composition is effectively provided by means of thecarrier.

A preferred carrier herein comprises a binderless (or optional lowbinder), hydroentangled absorbent material, especially a material whichis formulated from a blend of cellulosic, rayon, polyester and optionalbicomponent fibers. Such materials are available from Dexter, Non-WovensDivision, The Dexter Corporation as HYDRASPUN®, especially Grades 10244and 10444. The manufacture of such materials forms no part of thisinvention and is already disclosed in the literature. See, for example,U.S. Pat. Nos. 5,009,747, Viazmensky, et al., Apr. 23, 1991 and5,292,581, Viazmensky, et al., Mar. 8, 1994, incorporated herein byreference. Preferred materials for use herein have the followingphysical properties.

Dexter, Grade 10244 Optional Units Targets Range Basis Weight gm/m² 5535-75 Thickness microns 355  100-1500 Density gm/cc 0.155  0.1-0.25 DryTensile gm/25 mm MD 1700  400-2500 CD 650 100-500 Wet Tensile gm/25 mmMD* 700  200-1250 CD* 300 100-500 Brightness % 80 60-90 AbsorptionCapacity % 735     400-900 (H₂O) Dry Mullen gm/cm² 1050  700-1200 *MD -machine direction; CD - cross direction

As disclosed in U.S. Pat. Nos. 5,009,747 and 5,292,281, thehydroentangling process provides a nonwoven material which comprisescellulosic fibers, and preferably at least about 5% by weight ofsynthetic fibers, and requires less than 2% wet strength agent toachieve improved wet strength and wet toughness.

Coversheet—The coversheets which are employed herein to enrobe thecarrier sheet are distinguished from the carrier substrate sheets,inasmuch as the coversheets are relatively non-absorbent to the liquidcleaning/refreshment compositions as compared with the carrier sheets.The coversheets are constructed from hydrophobic fibers which tend notto absorb, “wick” or otherwise promote the transfer of fluids. Whilefluids can pass through the void spaces between the fibers of thecoversheet, this occurs mainly when excessive pressure is applied to thearticle. Thus, under typical usage conditions the coversheet provides aphysical barrier which keeps the absorbent carrier, which is damp fromits load of aqueous cleaning/refreshment composition, from coming intodirect contact with the fabrics being treated. Yet, the permeablecoversheet does allow vapor transfer of the cleaning/refreshmentcomposition from the carrier through the coversheet and into thecontainment bag, and thence onto the fabrics being treated.

In addition to providing the barrier function, the present invention nowprovides means whereby the coversheet also serves as a “trap” for lintand other particulate matter which is desirably removed from the fabricsbeing treated.

One type of coversheet herein comprises a fibrous, permeable nonwoven orwoven fabric. Such nonwoven or woven fibrous coversheets offeradvantages over formed-film type coversheets known in the catamenialsart. For example, formed-film coversheets (as described hereinafter) areoften manufactured by hydroforming processes which are particularlysuitable with polymer films such as polyethylene. While polyethylene canbe used herein, there is some prospect that, due to its lower meltingpoint, high dryer temperatures can cause its softening and/or meltingin-use. This is particularly true if the article herein were to bereleased from the containment bag and fall into the hot dryer drum.While it is possible to prepare formed-film topsheets using nylon,polyester or other heat resistant polymeric sheets, such manufacturebecomes somewhat more difficult and, hence, more expensive.

It has now also been determined that the coversheet herein should be ofa thickness which effectively provides the physical barrier function.Even though made from hydrophobic fibers, if the coversheet is too thin,fluid passage can occur under the intended usage conditions.Accordingly, it has now been determined that the thickness of thefibrous coversheet should preferably be at least about 7 mils (0.18 mm),preferably from about 0.2 mm to about 0.6 mm. It has also beendetermined that the fibers used in the coversheet are preferablyhydrophobic and preferably have a melting point above about 204° C.

Fibrous coversheets for use herein can readily be made from non-heatresistant fibers such as polyethylene. However, it has now beendetermined that preferred fibrous coversheets can be prepared usingnylon (especially nylon-6), polyester, and the like, heat-resistantfibers which can withstand even inadvertent misuse in the presentprocess. The flexible, cloth-like, permeable topsheets made therefromare conventional materials in the art of nonwoven and woven fabricmaking, and their manufacture forms no part of the instant invention.Nonwoven fabrics for use as coversheets are available commercially fromcompanies such as Reemay, Inc., Hickory, Tenn. Such coversheets alsopick up solid dust particles, vagrant lint and other fibers from thefabrics being treated in the present process, thereby enhancing theoverall clean/refreshed appearance of the fabrics following thetreatment herein.

Such nonwoven or woven fibrous sheet materials can be used in a flatsingle layer or as multiple layers as the coversheet for the absorbentcarrier core herein. In another embodiment, the absorbent core carryingthe cleaning/refreshment composition is enrobed in a polyester orpolyamide fibrous coversheet which has been ring rolled or otherwisecrimped to provide three dimensional bulk. Optionally, this coversheetmay be further covered by a second coversheet in an uncrimpedconfiguration.

Such fibrous, preferably heat resistant and, most preferably,hydrophobic, coversheets thus provide various embodiments of the articleherein. Suitable combinations can be employed, according to the desiresof the manufacturer, without departing from the spirit and scope of theinvention. If desired, the coversheet can be provided with macroscopicfenestrations through which the lint, fibers or particulate soils canpass, thereby further helping to entrap such foreign matter inside thearticle, itself.

A typical spun-bonded fibrous coversheet herein is commerciallyavailable from Reemay and has the following characteristics.

(a) Fabric Type—Non-woven, semi-dull, whitened homopolymer 100% virgin,spun-bonded polyester.

(b) Fiber Type—6.0 Denier straight, tri-lobal continuous fiber,copolymer polyester.

Web Properties Target Range a) Basis weight, roll average oz/yd² 0.540.52 to 0.59 b) Thickness 8 mil 7-8 mil c) Fuzz level As measured byReemay sled/drag method based on 0-5 scale. 5 being no fuzz level. Beltside 2.5 5.0 1.8 Jet side 3.4 5.0 2.6

As noted above, another type of coversheet which can be used with thearticles herein comprises the apertured “formed film” coversheets knownin the art and from commercial use on catamenials. Apertured formedfilms are pervious to the liquid cleaning and/or refreshmentcompositions and vapors thereof, and yet non-absorbent. Thus, thesurface of the formed film which is in contact with the fabrics remainsrelatively dry, thereby reducing water spotting and dye transfer. Aswith the fibrous coversheets, the apertured formed films capture andretain lint, fibrous matter such as pet hair, and the like, from thefabric being treated, thereby enhancing the cleaning/refreshmentbenefits afforded by the present articles. Suitable formed films aredescribed in U.S. Pat. No. 3,929,135, entitled “Absorptive StructureHaving Tapered Capillaries”, issued to Thompson on Dec. 30, 1975; U.S.Pat. No. 4,324,246, entitled “Disposable Absorbent Article Having AStain Resistant Coversheet”, issued to Mullane and Smith on Apr. 13,1982; U.S. Pat. No. 4,342,314, entitled “Resilient Plastic WebExhibiting Fiber-Like Properties”, issued to Radel and Thompson on Aug.3, 1982; and U.S. Pat. No. 4,463,045, entitled “Macroscopically ExpandedThree-Dimensional Plastic Web Exhibiting Non-Glossy Visible Surface andCloth-Like Tactile Impression”, issued to Ahr, Louis, Mullane andOuellete on Jul. 31, 1984; U.S. Pat. No. 4,637,819 issued to Ouellette,Alcombright & Curro on Jan. 20, 1987; U.S. Pat. No. 4,609,518 issued toCurro, Baird, Gerth, Vernon & Linman on Sep. 2, 1986; U.S. Pat. No.4,629,642 issued to Kemstock on Dec. 16, 1986; and EPO Pat. No.0,165,807 of Osborn published Aug. 8, 1989; all of which areincorporated herein by reference. The apertures in such coversheets maybe of uniform size or can vary in size, as disclosed in the foregoingpublished documents, which can be referred to for technical details,manufacturing methods, and the like. Such apertures may also vary indiameter in the manner of so-called “tapered capillaries”. Suchformed-film cover-sheets with tapered capillary apertures preferably aresituated over the carrier sheet such that the smaller end of thecapillary faces the carrier sheet and the larger end of the capillaryfaces outward. This helps prevent bulk liquid transfer, therebyminimizing water spotting on the fabrics being treated. In the main,apertures in the formed film coversheets used herein can have diametersin the range of from about 0.1 mm to about 1 mm, or as disclosed in theaforesaid patent references.

As shown in FIG. 1, an article (1) of the present type can be assembledas a laminate comprising a topmost fibrous sheet (1 a), an absorbentcarrier sheet as the core (1 b) and a bottommost fibrous sheet (1 c).The combination of topsheet and bottomsheet comprises the “coversheet”in the preferred embodiment of the articles herein. In this illustratedembodiment, the internal surfaces (1 d) of the topmost fibrous sheet iscoated with the tackiness agent (1 e). In another embodiment, both thetop and bottom sheets can contain the tackiness agent. In yet anotherembodiment, the tackiness agent can be on the outer surface of thecoversheet or on the outer surface of the carrier sheet (1 b). Asdescribed above, texture imparting indentations can be placed on any orall of the surfaces of the fibrous sheet 1(a), core (1 b), or fibroussheet (1 c).

The assembled laminate article (1) is shown in FIG. 2. FIG. 2 also showsthe bond (1 f) which extends around the periphery of the article. Thepurpose of this bond is to ensure that the absorbent carrier coremaintains its original configuration relative to the coversheet when thearticle is being used in the manner of this invention. Stated simply, ithas been discovered that if the absorbent sheet which comprises the coreis not bonded to the “envelope” provided by the coversheet in-use, thecarrier sheet tends to crumple and bunch-up inside the coversheet. Thiscan interfere with the delivery of the cleaning/refreshment compositionto the fabrics being treated.

Moreover, it has also been discovered that it is not preferred totightly bond the coversheet to the carrier sheet across the entire faceof the carrier sheet. Tightly bonding the coversheet closely to thecarrier sheet can allow some liquid transfer to occur through thecoversheet. Accordingly, the carrier sheet is preferably bonded to thecoversheet only in discrete areas. In one embodiment as shown in FIG. 2,this bonding is only around the periphery of the article. In anotherembodiment, spot-bonding at discrete areas across the face of thearticle can be employed. Various other bond patterns can be used.Preferably, the bonding is done at no more than about 50% of the area ofthe article, more preferably no more than about 10% of the area of thearticle, most preferably no more than about 1% of the area of thearticle.

Tackiness Agents—The tackiness agents employed herein are materialswhich are well-known in the art and are available commercially. Manysuch agents are proprietary chemicals whose compositions are maintainedas trade secrets. If desired, the manufacturer of the articles hereincan formulate various tackiness agents by referring to standardizedtexts and formularies. However, this is an unnecessary step, inasmuch ascommercial tackiness agents are entirely suitable for the purposes ofthis invention. Among such tackiness agents available under Trade Namesthere can be mentioned the following, which are given by way ofillustration for the convenience of the manufacturer of the articlesherein and not by way of limitation: ELMER'S SPRAY ADHESIVE; SUPER 77,available from the 3M Company and Fuller's Roll-on Adhesive HL-2115-X.

In use, the tackiness agent is applied to the surface of the fibrouscoversheet employed herein. It has been determined experimentally thatsome tackiness agents may be sufficiently aggressive that they canactually remove fibers from the fabric more aggressively than is desiredfor simple cleaning purposes. Said another way, the more aggressivetackiness agents can actually degrade the garments by removing fibersfrom their weave. This, of course, would be unacceptable in an articlewhich is employed for cleaning/refreshing garments. In order to overcomethis unexpected problem, it has now been determined that it is preferredto apply the tackiness agent on the inner surface of the coversheetmaterial. During use for cleaning/refreshment purposes, lint, extraneousfibrous material and other miscellaneous particulate detritus passthrough the coversheet and become entrapped on the inside surface of thecoversheet by the layer of tackiness agent. When used in this manner,the tackiness agent holds the solid detritus quite satisfactorily, yetdoes not degrade the weave of the fabric per se.

The amount of tackiness agent can vary with the type of agent selected.In general, from about 200 mg to about 70,000 mg of tackiness agent persquare meter of coversheet is employed. This can vary with the agentselected. For example, with ELMER'S (E-452), the preferred amount isabout 4000 mg/m², with a range from about 265 to about 26,500 mg/m².With 3M's SUPER 77 the preferred amount is about 6200 mg/m², with arange from about 620 to about 62,000 mg/m². Accordingly, it will be seenthat the present invention employs an “effective amount” of thetackiness agent which is an amount sufficient to retain lint and fibrousand/or particulate matter released for the fabrics beingcleaned/refreshed. The “effective amount” will vary not only with thetype of tackiness agent selected, but also with the load offibrous/particulate matter being handled. However, such amounts can bedetermined by routine experimentation in light of the disclosuresherein. The tackiness agent can be applied using any convenienttechnique such as spraying, rolling, padding, and the like.

Cleaning/Refreshment Compositions—The user of the present process canemploy various cleaning/refreshment compositions to practice theinvention. However, one potential problem associated with many knownfabric treatment compositions is their tendency to leave visibleresidues on fabric surfaces. Such residues are problematic and arepreferably to be avoided herein since the present process does notinvolve conventional immersion or rinse steps. Accordingly, thecompositions used herein should, most preferably, be substantially freeof various gelling agents, polyacrylate-based emulsifiers, polymericanti-static agents, inorganic builder salts and other residue-formingmaterials, except at low levels of about 0.1%-0.3%, and preferably 0%,of the final compositions. Water used in the compositions shouldpreferably be distilled, deionized or otherwise rendered free ofresidue-forming materials. Stated otherwise the compositions hereinshould preferably be formulated so as to leave substantially no visibleresidue on fabrics or other solid surfaces being treated according tothe practice of this invention.

Aqueous Compositions

(a) Water—The preferred, low residue compositions herein may comprisefrom about 90%, preferably from about 95.5% to about 99.9%, by weight,of water.

(b) Surfactant—The compositions herein preferably comprise from about0.05% to about 2%, by weight, of surfactants, especially nonionics suchas the ethoxylated C₁₀-C₁₆ alcohols, e.g., NEODOL 23-6.5.

(c) Optionals—The compositions herein may comprise minor amounts ofvarious optional ingredients, including preservatives, bleachstabilizers, perfumes, pH adjusters, buffers, and the like. If used,such optional ingredients will typically comprise from about 0.05% toabout 2%, by weight, of the compositions, having due regard for residueson the cleaned fabrics.

The following illustrates preferred ranges for cleaning/refreshmentcompositions for use herein, but is not intended to be limiting thereof.

Ingredient % (wt.) Formula Range Surfactant 0-2 Perfume   0-1.5 WaterBalance pH range from about 5 to about 8.

Preferred compositions for use in the in-dryer cleaning/refreshmentprocess herein are as follows.

Ingredient % (wt.) Range (% wt.) Water 99.0 95.1-99.9 Perfume 0.5  0-1.5 Surfactant* 0.5 0.05-2.0  Ethanol or Isopropanol 0 Optional to4% *Especially ethoxylated alcohols, as disclosed herein. Commercialsurfactants available as TWEEN ®, SPAN ®, AEROSOL OT ® and varioussulfosuccinic esters are especially useful herein.

Perfume—It has been determined that higher molecular weight, highboiling point, malodorous chemicals tend to be retained on the fabrics,at least to some degree. These malodors can be overcome, or “masked”, byperfumes. Accordingly, it will be appreciated that the perfumer shouldselect at least some perfume chemicals which are sufficiently highboiling that they are not entirely lost during the process. A widevariety of aldehydes, ketones, esters, acetals, and the like, perfumerychemicals which have boiling points above about 50° C., preferably aboveabout 85° C., are known. Such ingredients can be delivered to thefabrics being treated by means of the carrier substrate herein duringthe processes herein, thereby helping to reduce the user's perception ofmalodors. Non-limiting examples of perfume materials with relativelyhigh boiling components include various essential oils, resinoids, andresins from a variety of sources including but not limited to orangeoil, lemon oil, patchouli, Peru balsam, Olibanum resinoid, styrax,labdanum resin, nutmeg, cassia oil, benzoin resin, coriander, lavandinand lavender. Still other perfume chemicals include phenyl ethylalcohol, terpineol and mixed pine oil terpenes, linalool, linalylacetate, geraniol, nerol, 2-(1,1-dimethylethyl)-cyclohexanol acetate,orange terpenes and eugenol. Of course, lower boiling materials can beincluded, with the understanding that some loss will occur due toventing.

Containment Bag—The compositions are loaded on the carrier substratewhich is encased in the coversheet and the finished article ispreferably stored in a pouch until time-of-use. The article is thenplaced in a bag environment for use in a heated operating clothes dryer,or the like, to treat fabrics as a dry cleaning alternative or fabricrefreshment process. The warm, humid environment created inside this bagvolatilizes malodor components in the manner of a “steam distillation”process, and moistens fabrics and the soils thereon. This moistening offabrics can loosen pre-set wrinkles, but it has now been discovered thatoverly wet fabrics can experience setting of new wrinkles during thedrying stage toward the end of the dryer cycle. Proper selection of theamount of water used in the process and, importantly, proper venting ofthe bag in the present manner can minimize wrinkling. Moreover, if thebag is not vented, the volatilized malodorous materials removed from thefabrics can undesirably be re-deposited thereon.

In a highly preferred mode, the process of the present invention employsa vapor-venting containment bag. The bag is preferably designed formultiple uses and reuses, and is especially adapted for use by theconsumer in any conventional hot air clothes dryer apparatus, such asthose found in the home or in commercial laundry/cleaningestablishments. The bag is designed to vent water and other vapors(including malodorous materials) which emanate from within the bag whenused in the manner described herein. The vapors released from the bagare thence exhausted through the air vent of the dryer apparatus.

The preferred venting bag is provided with a vapor-venting closure whichprovides one or more gaps through which vapors are released from thebag, in-use. In a preferred embodiment, the size of this gap is selectedto provide controlled vapor release from the bag under the indicatedoperating conditions. While other gap sizes and operating conditions canbe used, a preferred balance between vapor containment within the bag toperform the sanitization of the fabrics along with thecleaning/refreshment function and vapor release from the bag has nowbeen determined using the principles disclosed hereinafter.

Alternatively, the bag can be provided with a series of holes or otherfenestrations which provide vapor venting. However, such venting is notas effective as the vapor-venting closure.

In one mode, the present invention employs a vapor-venting containmentbag comprising an open end, a closed end and flexible side walls havinginner and outer surfaces, the open end of the bag having a section ofone side wall extending beyond the open end to provide a flexible flap,the flap having first fastening device affixed thereto, the flap beingfoldable to extend over a portion of the outside surface of the opposingside wall, the flap being affixable to the outer surface of the opposingwall of the bag by engaging the first fastening device on the insideface of the flap with a second fastening device present on the outsideface of the opposing side wall, the first and second fastening devices,when thus engaged, forming a fastener, thereby providing a closure forthe open end of the bag. The first and second fastening devices aredisposed so as, when engaged, to provide vapor-venting along theclosure, especially at the lateral edges of the closure. The bag hereinis most preferably formed from film which is heat resistant up to atleast about 204° C.-260° C. Nylon is a preferred film material forforming the bag. In another embodiment, the edge of one wall of the bagis notched along a substantial portion of its width to facilitate andoptimize vapor venting.

In an alternate mode, the flap can be folded to provide the closure,tucked inside the opposing side wall, and secured there by a fastener.In this mode, vapors are vented along the closure and especially at thelateral edges of the closure. In yet another mode, the side walls are ofthe same size and no flap is provided. Fastening devices placedintermittently along portions of the inner surfaces of the side wallsare engaged when the lips of the side walls are pressed together toprovide closure. One or more vapor-venting gaps are formed in thoseregions of the closure where no fastening device is present.

While the fastening devices herein can comprise chemical adhesives, thebag is preferably designed for multiple uses. Accordingly, reusablemechanical fasteners are preferred for use herein. Any reusablemechanical fastener or fastening means can be used, as long as theelements of the fastener can be arranged so that, when the bag is closedand the fastener is engaged, a vapor-venting closure is provided.Non-limiting examples include: bags wherein the first and secondfastening devices, together, comprise a hook and loop (VELCRO®-type)fastener; hook fasteners such as described in U.S. Pat. No. 5,058,247 toThomas & Blaney issued Oct. 22, 1991; bags wherein the first and secondfastening devices, together, comprise a hook and string type fastener;bags wherein the first and second fastener devices, together, comprisean adhesive fastener; bags wherein the first and second fasteningdevices, together, comprise a toggle-type fastener; bags wherein thefirst and second fastening devices, together, form a snap-type fastener;as well as hook and eye fasteners, ZIP LOK®-style fasteners, zipper-typefasteners, and the like, so long as the fasteners are situated so thatvapor venting is achieved. Other fasteners can be employed, so long asthe vapor-venting is maintained when the bag is closed, and the fasteneris sufficiently robust that the flap does not open as the bag and itscontents are being tumbled in the clothes dryer. The fastening devicescan be situated that the multiple vapor-venting gaps are formed alongthe closure, or at the lateral edges, or so that the gap is offset toone end of the closure. In yet another embodiment, both ends of the bagare provided with a vapor venting closure.

The design of the venting ability of the bag achieves a proper balanceof the above effects. A tightly-sealed, vapor impermeable “closed” bagwill not purge malodors and will overly moisten the fabrics, resultingin wrinkling. An overly “open” bag design will not sufficiently moistenthe fabrics or soils to mobilize heavier malodors or to removepre-existing fabric wrinkles. Further, the bag must be “closed” enoughto billow and create a void volume under water vapor pressure, whereinthe fabrics can tumble freely within the bag and be exposed to thevapors.

The bag is designed with sufficient venting to trap a portion of watervapors (especially early in the dryer cycle) but to allow most of thewater to escape by the end of the cycle. Said another way, the rate ofvapor release is, preferably, optimized to secure a balance of vaporventing and vapor trapping. A preferred bag design employs a water vaporimpermeable film such as nylon, with a the closure flap (preferably witha hook-and-loop VELCRO®-type fastener) like that of a large envelope.The degree of slack in the fold-over portion of the closure flap can bevaried to provide a vapor-venting air gap or partial opening whichcontrols the rate of vapor venting from of the bag. In another mode, anotch is cut along the edge of the side wall opposite the flap tofurther adjust the venting. The fastener devices shown in the Figuresrun only partly along the closure, thereby allowing venting to alsooccur at the lateral edges of the closure.

The following is intended to assist the formulator in the manufactureand use of vapor-venting bags in the manner of this invention, but isnot intended to be limiting thereof.

Bag Dimensions—FIG. 4 shows the overall dimensions of a notched bag:i.e., length (7) to fold line 27⅝ inches (70.2 cm); width (8) of bag 26inches (66 cm), with a flap to the base of the fold line (11) of 2⅜inches (6 cm). In the Tests reported hereinafter, this bag is referredto by its open dimensions as “26 in.×30 in.” (66.04 cm×76.20 cm).

FIG. 5 gives additional details of the positioning of the variouselements of the notched bag. In this embodiment, all dimensions are thesame for both the left hand and right hand sides of the bag. Thedimensions herein are for an opened bag which is about 30 inches (76.2cm) in overall length (including the flap) and about 26 inches (66 cm)wide. The distance (9) from the lateral edge of the bag to the outermostedge of the fastening device (3) located on the inside of the flap (5)is about 2 inches (5 cm). In this embodiment, the fastening device (3)on the inside of wall (2 a) comprises the loop portion of a VELCRO®-typestrip whose width (13) is about 0.75 inches (1.9 cm) and whose totallength is about 22 inches (55.9 cm). Fastening device (6) is similarlysituated on the outside of wall 2(b) and comprises the hook portion of a¾ inch (1.9 cm) VELCRO®-type strip. Distance (9) can be decreased orincreased to decrease or increase venting at the edges of the flap whenthe bag is closed and the fastener is engaged. The distance (10) betweenthe uppermost edge of the flap and the base of the notch is about 2⅞inches (7.3 cm). The distance (14) between the lateral edge of the bagand the lateral edge of the notch is about 0.25 inches (0.64 cm). Thedistance (15) between the uppermost edge of the flap and the fold (11)is about 2⅜ inches (6 cm). The distance (16) between the uppermost edgeof the flap and the leading edge of the VELCRO®-type strip (3) affixedto the flap is about ⅜ inches (0.95 cm). The distance (17) between fold(11) and the lowermost edge of the notch is about ½ inch (1.27 cm). Thisdistance also can be varied to decrease or increase vapor venting. Arange of 0.25-1.5 inches (0.64-3.81 cm) is typical. The distance (18)between the uppermost edge of the VELCRO®-type strip (6) and the bottomedge of the notch is about ¾ inches (1.9 cm). The distance (19) betweenthe bottommost edge of the VELCRO®-type strip (3) and the fold (11) isabout 1¼ inches (3.17 cm).

FIG. 6 gives additional details of the dimensions of an un-notchedenvelope bag of the foregoing overall size comprising sidewalls (2 a)and (2 b). Again, each VELCRO®-type strip (3) and (6) is about ¾ inches(1.9 cm) in width and about 22 inches (55.9 cm) in length. Each strip ispositioned so as to be inboard from each of the lateral edges of thefinished bag wall and flap by about 2 inches (5 cm). The distance (12)between the leading edge of the sidewall (2 b) to the base edge of thefastener strip (3) on the flap portion of the bag is about 2½ inches(6.35 cm). The distance (20) between the base edge of the fastener strip(6) to the leading edge of the sidewall (2 b) is about 2.25 inches (5.7cm). The distance (21) between the leading edge of the fastener strip(6) to the leading edge of the sidewall is about 1⅜ inches (3.5 cm). Thedistance (22) between fold (11) and the base edge of the fastener strip(3) is about 2 inches (5 cm). The distance (23) between the leading edgeof fastener strip (3) and the uppermost edge of the flap which is anextension of sidewall (2 a) is about 0.25 inches (0.64 cm). Distance(24) is about 3⅝ inches (9.2 cm). As in the foregoing notched bag, thepositioning and length of the fasteners can be adjusted to decrease orincrease venting.

The construction of the preferred, heat-resistant vapor-venting bag usedherein to contain the fabrics in a hot air laundry dryer or similardevice preferably employs thermal resistant films to provide the neededtemperature resistance to internal self-sealing and external surfacedeformation sometimes caused by overheated clothes dryers. In addition,the bags are resistant to the chemical agents used in the cleaning orrefreshment compositions herein. By proper selection of bag material,unacceptable results such as bag melting, melted holes in bags, andsealing of bag wall-to-wall are avoided. In a preferred mode, thefastener is also constructed of a thermal resistant material. As shownin the Figures, in one embodiment, 1 to 3 mil (0.025-0.076 mm)heat-resistant Nylon-6 film is folded and sealed into a containment bag.Sealing can be done using standard impulse heating equipment. In analternate mode, a sheet of nylon is simply folded in half and sealedalong two of its edges. In yet another mode, bags can be made by airblowing operations. The method of assembling the bags can be varied,depending on the equipment available to the manufacturer and is notcritical to the practice of the invention.

The dimensions of the containment bag can vary, depending on theintended end-use. For example, a relatively smaller bag can be providedwhich is sufficient to contain one or two silk blouses. Alternatively, alarger bag suitable for handling a man's suit can be provided.Typically, the bags herein will have an internal volume of from about10,000 cm³ to about 25,000 cm³. Bags in this size range are sufficientto accommodate a reasonable load of fabrics (e.g., 0.2-5 kg) withoutbeing so large as to block dryer vents in most U.S.-style home dryers.Somewhat smaller bags may be used in relatively smaller European andJapanese dryers.

The bag herein is preferably flexible, yet is preferably durable enoughto withstand multiple uses. The bag also preferably has sufficientstiffness that it can billow, in-use, thereby allowing its contents totumble freely within the bag during use. Typically, such bags areprepared from 0.025 mm to 0.076 mm (1-3 mil) thickness polymer sheets.If more rigidity in the bag is desired, somewhat thicker sheets can beused.

In addition to thermally stable “nylon-only” bags, the containment bagsherein can also be prepared using sheets of co-extruded nylon and/orpolyester or nylon and/or polyester outer and/or inner layerssurrounding a less thermally suitable inner core such as polypropylene.In an alternate mode, a bag is constructed using a nonwoven outer“shell” comprising a heat-resistant material such as nylon orpolyethylene terephthalate and an inner sheet of a polymer whichprovides a vapor barrier. The non-woven outer shell protects the bagfrom melting and provides an improved tactile impression to the user.Whatever the construction, the objective is to protect the bag'sintegrity under conditions of thermal stress at temperatures up to atleast about 400-500° F. (204° C. to 260° C.). Under circumstances whereexcessive heating is not of concern, the bag can be made of polyester,polypropylene or any convenient polymer material.

Vapor Venting Evaluation—In its broadest sense, the preferredvapor-venting containment bag used herein is designed to be able to ventat least about 40%, preferably at least about 60%, up to about 90%,preferably no more than about 80%, by weight, of the total moistureintroduced into the bag within the operating cycle of the clothes dryeror other hot air apparatus used in the process herein. (Of course most,if not all, of organic cleaning solvents, if any, will also be ventedduring together with the water. However, since water comprises by farthe major portion of the cleaning/refreshment compositions herein, it ismore convenient to measure and report the venting as water vaporventing.)

It will be appreciated by those knowledgeable about the operation of hotair clothes dryers and similar apparatus that the rate of venting willusually not be constant over the entire operating cycle. All dryers havea warm-up period at the beginning of the operating cycle, and this canvary according to the specifications of the manufacturer. Most dryershave a cool-down period at the end of the operating cycle. Some ventingfrom the containment bag can occur during these warm-up and cool-downperiods, but its rate is generally less than the venting rate over themain period of the drying cycle. Moreover, even during the main periodof the cycle, many modern dryers are constructed with thermostatsettings which cause the air temperature in the dryer to be increasedand decreased periodically, thereby preventing overheating. Thus, anaverage, rather than constant, dryer operating temperature in the targetrange of from about 50° C. to about 85° C. is typically achieved.

Moreover, the user of the present containment bag may choose to stop theoperation of the drying apparatus before the cycle has been completed.Some users may wish to secure fabrics which are still slightly damp sothat they can be readily ironed, hung up to dry, or subjected to otherfinishing operations.

Apart from the time period employed, the Vapor-Venting Equilibrium(“VVE”) for any given type of vapor-venting closure will depend mainlyon the temperature achieved within the dryer—which, as noted above, istypically reported as an average “dryer air temperature”. In point offact, the temperature reached within the containment bag is moresignificant in this respect, but can be difficult to measure withaccuracy. Since the heat transmittal through the walls of the bag israther efficient due to the thinness of the walls and the tumblingaction afforded by conventional clothes dryers, it is a reasonableapproximation to measure the VVE with reference to the average dryer airtemperature.

Moreover, it will be appreciated that the vapor-venting from thecontainment bag should not be so rapid that the aqueouscleaning/refreshment composition does not have the opportunity tomoisten the fabrics being treated and to mobilize and remove thesoils/malodors therefrom. However, this is not of practical concernherein, inasmuch as the delivery of the composition from its carriersubstrate onto the fabrics afforded by the tumbling action of theapparatus occurs at such a rate that premature loss of the compositionby premature vaporization and venting is not a significant factor.Indeed, the preferred bag herein is designed to prevent such prematureventing, thereby allowing the liquid and vapors of thecleaning/refreshment composition to remain within the bag for a periodwhich is sufficiently long to perform its intended functions on thefabrics being treated.

The following Vapor-Venting Evaluation Test (VVET) illustrates theforegoing points in more detail. Larger or smaller containment bags canbe used, depending on the volume of the dryer drum, the size of thefabric load, and the like. As noted above, however, in each instance thecontainment bag is designed to achieve a degree of venting, or VVE“score”, of at least about 40% (40 VVE), preferably at least about 60%(60 VVE), up to about 90% (90 VVE). WO 97/27354 to Greene, Rogers,Saslow, Wise and You, incorporated herein by reference, providesgraphical figures illustrating the vapor venting of the bag.

Vapor-Venting Evaluation Test

Materials:

Envelope or “Standard”, i.e., Control Containment Bag to be evaluatedfor VVE.

Carrier Substrate (15″×11″; 38.1 cm×27.9 cm) HYDRASPUN® carriersubstrate sheet from Dexter with (10444) or without (10244) Binder

Wool Blouse: RN77390, Style 12288, Weight approx. 224 grams

Silk Blouse: RN40787, Style 0161, Weight approx. 81 grams

Rayon Swatch: 45″×17″ (114.3 cm×43.2 cm), Weight approx. 60 grams

Pouch: 5″×6.375″ (12.7 cm×16.2 cm) to contain the Carrier Substrate andwater De-ionized Water; Weight is variable to establish VVE.

Pretreatment of Fabrics:

1. The wool, silk, and rayon materials are placed in a Whirlpool dryer(Model LEC7646DQO) for 10 minutes at high heat setting, with the heatingcycle ranging from about 140° F.-165° F. to remove moisture picked up atambient condition.

2. The fabrics are then removed from the dryer and placed in sealednylon or plastic bags (minimum 3 mil. thickness) to minimize moisturepick up from the atmosphere.

Test Procedure:

1. Water of various measured weights from 0 to about 40 grams is appliedto the carrier substrate a minimum of 30 minutes before running a ventedbag test. The substrate is folded, placed in a pouch and sealed.

2. Each fabric is weighed separately and the dry weights are recorded.Weights are also recorded for the dry carrier substrate, the dry pouchcontaining the substrate, and the dry containment bag being evaluated.

3. Each garment is placed in the bag being evaluated for vapor ventingalong with the water-containing substrate (removed from its pouch andunfolded).

4. The bag is closed without expressing the air and placed in theWhirlpool Dryer for 30 minutes at the high heat setting, with tumblingper the standard mode of operation of the dryer.

5. At the end of 30 minutes the bag is removed from the dryer and eachfabric, the carrier substrate, the bag and the pouch are weighed forwater weight gain relative to the dry state. (A possible minor loss inweight for the containment bag due to dryer heat is ignored in thecalculations.)

6. The weight gain of each garment is recorded as a percent of the totalmoisture applied to the carrier substrate.

7. The remaining unmeasured moisture divided by the total moisture isrecorded as percent vented from the dryer bag.

8. When a series of total applied moisture levels are evaluated, it isseen that above about 15-20 grams of water the % vented becomesessentially constant, and this is the Vapor-Venting Equilibrium value,or VVE, for the particular bag venting design.

It can be seen from examining a series of VVET results at variousinitial moisture levels that the water at lower initial levels is beingdisproportionately captured by the garment load, the headspace, and thenylon bag, such that venting of water and volatile malodors begins inearnest only after the VVE value is achieved. Since this occurs onlywhen about 15-20 grams or more of water is initially charged, it is seenthat a VVE of greater than about 40 is needed to avoid excessive wettingof garments, leading to unacceptable wet-setting of wrinkles, asdiscussed herein.

Malodor and Wrinkle Removal

One assessment of the process using the vapor-venting bag herein withrespect to malodors comprises exposing the fabrics to be tested to anatmosphere which contains substantial amounts of cigarette smoke. In analternate mode, or in conjunction with the smoke, the fabrics can beexposed to the chemical components of synthetic perspiration, such asthe composition available from IFF, Inc. Expert olfactory panelists arethen used to judge odor on any convenient scale. For example, a scale of0 (no detectable odor) to 10 (heavy malodor) can be established and usedfor grading purposes. The establishment of such tests is a matter ofroutine, and various other protocols can be devised according to thedesires of the formulator.

For example, garments to be “smoked” are hung on clothing hangers in afume hood where air flow has been turned off and vents blocked. Sixcigarettes with filters removed are lighted and set in ashtrays belowthe garments. The hood is closed and left until the cigarettes haveabout half burned. The garments are then turned 180° to get evendistribution of smoke on all surfaces. Smoking is then continued untilall cigarettes are consumed. The garments are then enclosed in sealedplastic bags and allowed to sit overnight.

After aging for about one day, the garments are treated in thecleaning/refreshment process using the venting bag. The garments areremoved promptly from the containment bag when the dryer cycle isfinished, and are graded for malodor intensity. The grading is done byan expert panel, usually two, of trained odor and perfume graders. Themalodor intensity is given a grade of 0 to 10, where 10 is full initialintensity and 0 is no malodor detected. A grade of 1 is a tracedetection of malodor, and this grade is regarded as acceptably lowmalodor to most users.

In the absence of perfume ingredients in the cleaning cloth composition,the grading of residual malodor intensity is a direct indication ofdegree of cleaning or removal of malodorous chemicals. When perfumedcompositions are used, the grading panelists can also determine a scorefor perfume intensity and character (again on a 0 to 10 scale), and themalodor intensity grading in this case would indicate the ability of theresidual perfume to cover any remaining malodorous chemicals, as well astheir reduction or removal.

After the garment odor grading taken promptly after thecleaning/refreshment process, the garments are hung in an open room forone hour and graded again. This one-hour reading allows for anend-effect evaluation that would follow cool-down by the garments anddrying of the moisture gained in the dryer cycle treatment. The initialout-of-bag grading does reflect damp-cloth odors and a higher intensityof warm volatiles from the bag, and these are not factors in theone-hour grades. Further garment grading can be done at 24 hours and,optionally, at selected later times, as test needs dictate.

Likewise, fabric wrinkles can be visually assessed by skilled graders.For example, silk fabric, which wrinkles rather easily, can be used tovisually assess the degree of wrinkle-removal achieved by the presentprocesses using the vapor-venting bag. Other single or multiple fabricscan optionally be used. A laboratory test is as follows.

De-Wrinkling Test

Materials:

As above for VVET.

De-ionized Water, Weight range (0-38 grams)

Pretreatment of Fabrics:

The silk fabric is placed in a hamper, basket, or drum to simulatenormal conditions that are observed after wearing. These storageconditions produce garments that are severely wrinkled (well definedcreases) and require a moist environment to relax the wrinkles.

Test Procedure:

1. One silk fabric is placed in a containment bag being tested.

2. Water (0-38 grams) is applied to the carrier substrate a minimum of30 minutes before running the test, placed in a pouch and sealed.

3. The silk garment is placed in the test containment bag along with thewater-containing substrate (removed from its pouch and unfolded).

4. The bag is closed and placed in a Whirlpool Dryer (Model LEC7646DQO)for 30 minutes at high heat (48-74C cycle).

5. At the end of 30 minutes, the dryer bag is removed from the dryerIMMEDIATELY and the silk garment is placed on a hanger.

6. The silk garment is then visually graded versus the Control Garmentfrom the same Pretreatment Of Fabrics.

In laboratory tests of the foregoing type, the in-dryer, non-immersioncleaning/refreshment processes herein typically provide malodor(cigarette smoke and/or perspiration) malodor grades in the 0-1 rangefor smoke and somewhat higher for perspiration malodors, therebyindicating good removal of malodor components other than those ofsufficiently high molecular weights that they do not readily “steamvaporize” from the fabrics. Likewise, fabrics (silks) have wrinklesremoved to a sufficient extent that they are judged to be reasonablysuitable for wearing with little, or no, ironing.

Process Components

The use of the article with the vapor-venting bag, the compositions andthe processes of this invention are described in more detailhereinafter. Such disclosure is by way of illustration and notlimitation of the invention herein.

FIG. 3 illustrates one form of a pre-formed, notched containment bag inan open configuration with the loose, planar article (1), first sidewall (2 a), second side wall (2 b), first fastening device (3), sideseal (4) for the bag and flexible flap (5). In use, flexible flap (5) isfolded along fold line (11) to provide the vapor-venting closure for thebag.

FIG. 4 shows the “envelope-style” notched bag in a finishedconfiguration and containing the loose, planar article (1). In-use, thefabrics to be cleaned/refreshed are placed in the bag with the article(1) and flap (5) is folded along fold line (11) to engage firstfastening device (3) with the opposing second fastening device (6) tofasten the flap, thereby providing a vapor-venting closure which issufficiently stable to withstand tumbling in a hot air clothes dryer orsimilar device.

FIG. 5 shows a cut-away view of the corner of the notched containmentbag illustrating the interior of the first side wall (2 a) and secondside wall (2 b), first fastening device (3), second fastening device(6), flap (5), and fold line (11). The distance between the edge of thebag (9) and the depth of the notch (11) in second side wall (2 b) aredimensions which are set forth hereinabove.

FIG. 6 depicts an un-notched venting bag with the article (1) looselycontained therein.

As noted above, the Bag Dimensions given hereinabove are for containmentbags which are designed to tumble freely within the drum of aconventional, U.S. style in-home hot air clothes dryer having a drumvolume of about 170-210 liters (home size). The bag of the stateddimensions is designed to treat up to about 5 kg fabric load in a singleuse. The dimensions can be adjusted proportionately for larger orsmaller bags to achieve the desired VVE and to ensure effective use indryers with larger or smaller drums. For example, the total volume of acontainment bag constructed for use in an average European home clothesdryer (or U.S. “apartment” size; ca. 90 liter drum volume) would beabout 60% of the volume for an average U.S. dryer.

Overall Process

The overall process is conveniently conducted in a tumbling apparatus,preferably in the presence of heat. The nylon or other heat-resistantvapor-venting bag with the article herein plus aqueouscleaning/refreshment composition and containing the fabric being treatedis closed and placed in the drum of an automatic hot air clothes dryerat temperatures of 40° C.-150° C. The drum is allowed to revolve, whichimparts a tumbling action to the bag and agitation of its contentsconcurrently with the tumbling. By virtue of this agitation, the fabricscome in contact with the article containing the composition. Thetumbling and heating are carried out for a period of at least about 10minutes, typically from about 20 minutes to about 60 minutes. This stepcan be conducted for longer or shorter periods, depending on suchfactors as the degree and type of soiling of the fabrics, the nature ofthe soils, the nature of the fabrics, the fabric load, the amount ofheat applied, and the like, according to the needs of the user. Duringthe step, greater than about 40%, typically 40% to about 80%, of themoisture is vented from the bag.

With respect to the wrinkle-removing function of the process andcompositions herein, it will be appreciated that wrinkling can beaffected by the type of fabric, the fabric weave, fabric finishes, andthe like. For fabrics which tend to wrinkle, it is preferred not tooverload the vapor-venting bag used herein. Thus, for a bag with, forexample, an operational capacity of up to about 5 kg of fabrics, it maybe best to process up to only about 60% of capacity, (i.e., up to about3 kg) of fabrics to further minimize wrinkling.

The following examples further illustrate the invention, but are notintended to be limiting thereof.

EXAMPLE I

A low residue liquid fabric cleaning/refreshment product for usepreferably in a vented dryer bag is prepared, as follows.

Ingredient % (wt.) Emulsifier (TWEEN 20)* 0.5 Perfume 0.5 KATHON ®**0.0003 Sodium Benzoate 0.1 Water Balance *Polyoxyethylene (20) sorbitanmonolaurate available from ICI Surfactants. **Preservative

A 10¼ in.×14¼ in. (26 cm×36 cm) carrier sheet of HYDRASPUN® is prepared.The carrier sheet is covered on both sides with a topsheet and abottomsheet of 8 mil (0.2 mm) Reemay fabric coversheet material of thetype described hereinabove. The coversheet is coated on its internalsurface with about 4000 mg of ELMER'S SPRAY ADHESIVE (or about 6200 mgof 3M's SUPER 77 Spray Adhesive) tackiness agent per square meter. Thecoversheet (i.e., both topsheet and bottomsheet) are bonded to thecarrier sheet by a Vertrod® or other standard heat sealer device,thereby bonding the laminate structure together around the entireperiphery of the carrier sheet. The edges of the carrier sheet aroundits periphery are intercalated between the topsheet and bottomsheet bythe bond. The width of the bond is kept to a minimum and is about 0.25in. (6.4 mm).

The bonded laminate structure thus prepared is rolled somewhat looselyaround a cylindrical void into a generally tubular shape of about 26 cmlength and a diameter of about 2-3 cm. The rolled article is then foldedto half its length at about its mid-point by means of a thrusting bladewhich also serves to insert the article into a retaining pouch. It isobserved that, with the rolling method herein, essentially no severelysharp creases are formed, and the final doubling of the rolled tube isunder such stress that only in the very center of the bend are a fewsharper creases formed. The result is that permanent refolding alongcrease lines is essentially avoided, and release of thecleaning/refreshment composition from the article in-use is optimized.

Any plastic or flexible pouch which does not leak is suitable for useherein. For example, a foil laminated pouch of the type used in the foodservice industry can be employed. Such pouches are well-known in theindustry and are made from materials which do not absorb food flavors.In like manner, the formulator herein may wish to avoid absorption ofthe perfume used in the cleaning/refreshment composition by the pouch.Various pouches are useful herein and are commercially available on aroutine basis. As a point of comparison, the pouch containing therolled/folded article herein has overall dimensions of about 8.5 cm×17.7cm, whereas a pouch for a similar planar-folded article is about 13cm×17.7 cm. A savings in material of about 30-40% is thus achieved.

20 Grams of the liquid product are poured onto the article within thepouch and allowed to absorb into it for a minimum of 30 minutes,preferably for at least about 4 hours. The pouch is sealed immediatelyafter the liquid product is introduced into the pouch and stored untiltime-of-use.

As an entirely optional matter, and in addition to the texture impartingindentations discussed above, the carrier sheet can also have holespunched therethrough in order to further maximize its ability tomaintain an open configuration in-use. Indeed, the holes can be punchedthrough the entire article, including the coversheet, itself. For anarticle having the overall dimensions of about 27 cm×37 cm, 16 roundholes, each about 0.5 in. (1.27 cm) in diameter are evenly spaced acrossthe HYDRASPUN carrier sheet. Slits or other perforations may be used inlike manner.

The fabric to be treated is placed into a 26 in.×30 in. (66×76 cm)vapor-venting nylon bag as shown in the Figures together with thearticle (which is removed from its storage pouch, unfolded and unrolled)releasably containing the aforesaid cleaning/refreshment product. Themouth of the bag is closed to provide vapor-venting, and the bag and itscontents are placed in the drum of a conventional hot air clothes dryer.The dryer is operated in standard fashion for 20-60 minutes at a highheat setting (an air temperature range of about 140-170° F.; 60-70° C.).After the tumbling action of the dryer ceases, the cleaned and refreshedfabric is removed from the bag. Lint from the fabric is removedtherefrom and is retained by the coversheet. The used article isdiscarded. The fabric (which is preferably still slightly damp) ispreferably hung on a conventional hanger to complete the drying processthereby further avoiding wrinkles.

It will be understood that the articles herein can be modified withoutdeparting from the spirit and scope of this invention. For example, onevariation that can make the substrate a bit easier to fold and insertinto the pouch is to elongate the spiral fold pattern out, such that therolled fabric resembles a “bolted” roll of fabric. This bolting reducesthe number of cross-sectional layers versus a circular spiral, thuscausing less bunching and bulging along the center fold. Anothervariation is to fold the substrate first, preferably along its longestdimension, and then “bolt” or roll it. This pattern and the internalbunching of the layers produce a “springiness” to help keep the spiralpattern pushed open and prevent the folds from reforming in-use. Allsuch variations are encompassed by the terms “roll” or “rolled”, as usedherein. Alternatively, the rolled article can be folded into thirds,rather than half, to further minimize the use of packaging materials.Various logos, patterns, colors, and the like can be used to enhance theappearance of the articles.

EXAMPLE II

High water content cleaning/refreshment compositions for use in theprocess herein are as follows. The compositions are used in the mannerdisclosed hereinabove to clean and refresh fabrics.

Components Percent Range (%) Function Water De-ionized 98.8997   97-99.9Vapor Phase Cleaning TWEEN 20 0.50 0.5-1.0 Wetting Agent, Emulsifier forPerfume Perfume 0.50  0.1-1.50 Scent, Aesthetics KATHON CG* 0.00030.0001-0.0030 Anti-bacterial Sodium Benzoate* 0.10 0.05-1.0  Anti-fungal*Optional preservative ingredients.

20-30 Grams, preferably about 20 grams, of the Sweet Water compositionare absorbed into a 28 cm×38 cm HYDRASPUN® carrier sheet (the sheet ispreferably not “dripping” wet). The sheet is covered with the fibrouscoversheet whose internal (or, optionally, external) surface is coatedwith about 6200 mg of SUPER 77 (or about 4000 mg of ELMER'S SPRAYADHESIVE) tackiness agent per meter². The article is folded for storage.The article is unfolded and used in the foregoing manner to clean andrefresh fabrics in a hot air clothes dryer.

Auxiliary Cleaning Agents—In addition to the other ingredients, theforegoing liquid compositions can contain enzymes to further enhancecleaning performance. Lipases, amylases and protease enzymes, ormixtures thereof, can be used. If used, such enzymes will typicallycomprise from about 0.001% to about 5%, preferably from about 0.01% toabout 1%, by weight, of the composition. Commercial detersive enzymessuch as LIPOLASE, ESPERASE, ALCALASE, SAVINASE and TERMAMYL (all ex.NOVO) and MAXATASE and RAPIDASE (ex. International Bio-Synthesis, Inc.)can be used.

If an antistatic benefit is desired, the compositions used herein cancontain an anti-static agent. If used, such anti-static agents willtypically comprise at least about 0.5%, typically from about 2% to about8%, by weight, of the compositions. Preferred anti-stats include theseries of sulfonated polymers available as VERSAFLEX 157, 207, 1001,2004 and 7000, from National Starch and Chemical Company.

Cleaning solvents, e.g., butoxy propoxy propanol and spreading agentssuch as 1,2-octanediol can optionally comprise up to about 5%, byweight, of the compositions.

What is claimed is:
 1. An article for treating fabrics comprising: a) anabsorbent substrate; b) a liquid cleaning/refreshment compositionreleasably absorbed in the substrate; the substrate being wholly orpartly covered by; c) a coversheet which is permeable to thecleaning/refreshment composition in the liquid and/or vapor state, thecoversheet having an external surface and an internal surface, i.wherein the internal surface of the coversheet is bonded to theabsorbent substrate around the periphery of the article and in a mannersuch that less than the entire coversheet is bonded to the absorbentsubstrate; and ii. wherein the article further comprises a tackinessagent that is present on the external surface of the coversheet or onthe internal surface of the coversheet in areas where the internalsurface of die coversheet is not bonded to the absorbent substrate or onthe absorbent substrate in areas where the internal surface of thecoversheet is not bonded to the absorbent substrate wherein thetackiness agent is in an unactivated state such that it does not bondthe coversheet to the absorbent substrate until subjected to elevatedtemperatures.
 2. An article according to claim 1, wherein the tackinessagent is on the internal surface of the coversheet.
 3. An articleaccording to claim 1 wherein the coversheet is fibrous.
 4. An articleaccording to claim 1 wherein the coversheet is an apertured formed film.5. An article according to claim 1 wherein the tackiness agent is on thesurface of the absorbent substrate.
 6. An article according to claim 1wherein the cleaning/refreshment composition comprises water and amember selected from the group consisting of organic surfactants,organic solvents, auxiliary cleaning agents, and mixtures thereof.
 7. Anarticle according to claim 1 wherein the cleaning/refreshmentcomposition comprises water and a surfactant.
 8. An article according toclaim 7 wherein the surfactant is a nonionic surfactant.
 9. An articleaccording to claim 8 wherein the cleaning/refreshment compositioncomprises a mixture of water and a surfactant which is an ethoxylatedalcohol, ethoxylated alkyl phenol or ethoxylated sorbitan fatty acidester.
 10. A process for cleaning and refreshing a fabric, comprisingcontacting the fabric with an article according to claim
 1. 11. Aprocess according to claim 10 which is conducted in a vapor-venting bagin a hot air clothes dryer.
 12. An article for treating fabrics,comprising: a) an absorbent substrate having a first surface and asecond surface; b) a liquid cleaning/refreshment composition releasablyabsorbed in the substrate; c) the substrate having a texture impartingpattern of indentations on at least one of the surfaces, the substratebeing wholly or partly covered by; d) a coversheet which is permeable tothe cleaning/refreshment composition in the liquid and/or vapor state,the coversheet having an external surface and an internal surface, i.wherein the internal surface of the coversheet is bonded to theabsorbent substrate around the periphery of the article and in a mannersuch that less than the entire coversheet is bonded to the absorbentsubstrate; and ii. wherein the article further comprises a tackinessagent that is present on the external surface of the coversheet or onthe internal surface of the coversheet in areas where the internalsurface of the coversheet is not bonded to the absorbent substrate or onthe absorbent substrate in areas where the internal surface of thecoversheet is not bonded to the absorbent substrate wherein thetackiness agent is in an unactivated state such that it does not bondthe coversheet to the absorbent substrate until subjected to elevatedtemperatures.